california sidecar trike conversion kit installation instructions valkyrie
Contents
1. Nyloc Nuts 12 3 8 24x1HHCS L 2 3 8 24 Nyloc Nut California Sidecar Parts amp Technical Support 100 Motorcycle Run Arrington VA 22922 PHONE 434 263 8866 FAX 434 263 8877 CALIFORNIA SIDECAR VALKYRIE INTERSTATE TRIKE CONVERSION KIT INSTALLATION INSTRUCTIONS STEP 1 PREPARING THE MOTORCYCLE Remove the following items INACCORDANCE WITH THE SERVICE MANUAL EON ST RS Rider seat save 9 Right and left rider foot rests save Side covers save 10 Right and left passenger foot rests save Saddle bag guards if installed ll Passenger foot rests support brackets Saddle Bags 12 Exhaust system save Saddle bag mounting brackets 13 Side stand Tour Box save 14 Back half of rear fender Antenna amp mount save Note Disconnect 15 Leaving wires as long as possible cut off and antenna cable before removing save electrical plug from rear section of fender Tour Box mounting brackets save Note a new rear mount bracket is supplied with the installation kit STEP 2 REMOVING REAR WHEEL amp SWING ARM Remove the following items INACCORDANCE WITH THE SERVICE MANUAL wR amp D Drain brake fluid 8 Remove U joint boot from engine case Remove rear wheel 9 Remove Swing arm Remove both shocks 10 Remove U joint boot from swing arm save Remove final drive unit 1l Remove drive shaft from final drive unit Remove rear brake caliper and brake lineto 12 Remove C clip spring and cup washer from rear2. Cn a gt alforna Ste Car ice fs TRIKE OM gt ESCAPADE CALIFORNIA SIDECAR TRIKE CONVERSION KIT INSTALLATION INSTRUCTIONS VALKYRIE INTERSTATE FOR INSTALLATION ASSISTANCE CALL PARTS amp TECHNICAL SUPPORT 434 263 8866 TABLE OF CONTENTS SECTION Table of Contents Introduction Parts List Accessory Parts List Step l Preparing the Motorcycle Step 2 Removing the Rear Wheel and Swing Arm Step 3 Installing the New Swing Arm Step 4 Installing the Rear End Step 5 Installing the Air Shock Mounting Bracket Step 6 Installing the Body Frame Step 7 Installing the Progressive Shocks to the Motorcycle Frame Step 8 Installing the Shocks to the Swing Arm Step 9 Modifying the Exhaust System Step 10 Installing the Air Shock Hose Tubing Step 11 Installing the Body Step 12 Installing the Wheels Step 13 Installing the Passenger Foot Rests Step 14 Installing the Wiring Step 15 Completing Installation PAGE 10 10 Il Il Il Il INTRODUCTION DISCLAIMER These instructions assume a level of understanding of motorcycle repair and maintenance beyond that of a beginner or novice and California Sidecar cannot be liable for an installer s failure to understand or follow these instructions as written Likewise California Sidecar cannot be responsible if any of the steps are omitted or shortcuts are taken or parts other than those supplied by CSC are used in installing this trike conver
3. align to body frame muffler mount tabs repeat steps 9 3 and 9 4 STEP 10 INSTALLING THE AIR SHOCK AIR HOSE TUBING L Route air shock inlet tube to left side of front panel where the seat key release is and drill 5 16 hole next to the seat key release 2 Insert air shock inlet valve and secure with nut supplied STEP l INSTALLING THE BODY 1 Be sure all previous steps are complete 2 Place body on frame in a downward motion from above bike 3 Using a 2 X 4 or block hold the front of body up so that you can re install all 4 pieces of the tour box mounting frame Note The rear bracket is now supplied with the kit 4 Align the body to the bike frame and wheels Lift carpet up in areas where you will be drilling 5 Drill six 6 5 16 holes through body using holes in body frame as guide Be certain to pull inside trunk carpet out of the way of the holes to be drilled 6 Fasten body using the following bolts Rear four 4 5 16 x 18 x 3 bolts with eight 8 5 16 USS flat washers four 4 5 16 x 18 nyloc nuts Front two 2 5 16 x 18 x 1 bolts with two 2 5 16 x 1 1 2 fender washers two 2 5 16 x 18 nyloc nuts 7 Re install Tour Box and antenna to new rear mount Run coaxial cable between tour box and trike body to the plug under the seat STEP 12 INSTALLING THE WHEELS L Install wheels with lug nuts provided and torque to 70 Ibs Re check after 25 miles 2 Install center caps with CSC logo 3 I
4. er cylinder to allow enough clearance to reinstall master cylinder cover Using 12 wire ties tie brake line to swing arm in at least 4 places and make sure it is clear of all obstructions and or areas where it could be damaged or pinched Using DOT 4 brake fluid bleed all air from brake lines Add 3 pints orl quarts of 80 90 wt gear oil to final drive unit Grease rear U joint Push front yoke dust boot back over output shaft and on to engine case INSTALLING THE AIR SHOCK MOUNT Drill out with 25 64 drill bit all the way through frame on both sides at the front and rear hole where passenger back rest was mounted Install air shock to mounting bracket with filler pipe pointing forward to front of bike Be certain the clevis on the air shock mount points to front of bike Install air line adapter with air tube to air shock Place air shock and mount into position be certain the air line opening on shock is facing front of bike Install FRONT air shock mount bolts in the following sequence M10 x 1 25 x 80 bolt 1 M10 washer body hanger 3 M10 washers then position bolt through motorcycle frame and air shock mount and fasten with M10 x 1 25 nyloc nut Repeat step 5 for the other side of bike Install REAR air shock mount bolts in the following sequences M10 X 1 25 X 100 1 washer through the chrome fender rail then through fender hanger bracket and air shock mount then add 3 washers and a 1 nyloc nut Repeat step 7 for the
5. master cylinder drive shaft save Remove swing arm pivot lock nut save 13 Save front U joint and yoke RETURN TO CALIFORNIA SIDECAR as core parts Remove both swing arm pivot bolts STEP 3 INSTALLING THE NEW SWING ARM FRAME Install C clip spring and cup washer to new drive shaft Lightly grease spring and splines of new drive shaft Place drive shaft through swing arm and install new front yoke BECERTAIN THAT ALIGNMENT MARKS LINE UP PROPERLY Lightly compress and tie both U joints together with wire through new swing arm frame Install U joint boot on swing arm Install swing arm onto bike frame using new swing arm pivot bolts Refer to the service manual for proper procedure Note Do not loosen or cut wire Step 3 4 above holding drive shaft Torque to Honda specs listed below Right Left Lock STEP 4 1 2 3 6 G 8 9 STEP 5 1 8 STEP 6 103 NM 19 NM 113 NM 76ft lbs 14 ft lbs 83 ft lbs INSTALLING THE REAR END Move the rear end into position with the swing arm Install eight 8 1 2 x 20 nyloc nuts and torque to 55 lbs Cut and remove wire installed in Step 3 4 Install U bolts to rear drive yoke and torque to 20 lbs Be certain that the bearing offsets in the yoke and the U joint are properly aligned Route braided brake line forward from T fitting around to right side of frame and attach to master cylinder using OEM banjo bolt It is necessary to bend brake line at mast
6. nflate tires to 20 25 lbs of air pressure STEP 13 INSTALLING PASSENGER FOOT RESTS NOTE The footrest can be placed in two positions whichever is more comfortable for the passenger 10 Position footrest plates on body frame just in front of fender with top of plate flush with top of body frame Mark the two holes and drill out with 3 8 drill bit Install two 2 3 8 x 16 x 1 1 2 button socket head bolts through foot rest plate and body frame Next install 3 8 x 16 nyloc nuts and torque to 20 lbs Repeat the above procedure for the opposite side Fasten footrest to plate with M10 x 1 25 x 35 bolt and M10 lock washer and tighten STEP 14 INSTALLING THE WIRING l Cut to length and crimp an appropriate terminal end to wire and connect to battery red black to positive and white to negative Route small black antenna wire to the body frame anywhere and wrap around metal frame several times Connect wires from trike body to OEM plug removed in Step 2 3 as follows Motorcycle Trike Kit Light Blue gt Light Blue Brown gt Brown Green gt Green Orange gt Orange Green w Red brake Green Red STEP 15 COMPLETING INSTALLATION l Re install antenna and Tour Box to new rear mount Run coaxial cable between tour box and new trike body then plug under the seat 2 Check all lighting on the motorcycle and trike body for proper operation California Sidecar Parts amp Technical Support 100 Motorc
7. other side of bike INSTALLING THE BODY FRAME STEP 7 Place body frame into position Install four 4 chrome M10 x 1 25 x 35 socket head bolts with four 4 M10 washers through holes 2 on each side and fasten where the passenger footrest brackets were mounted Torque to 55 lbs Install all eight 8 3 8 x 24 x 14 Gr 8 bolts each with two 2 SAE flat washers and one 1 x 24 nyloc nut connecting the body hanger brackets front and rear to body frame Torque to 40 lbs INSTALLING THE PROGRESSIVE SHOCKS TO THE MOTORCYCLE FRAME Before installing the Progressive shocks it necessary to set the preload These shocks come from the factory set at their lowest rebound setting and can be adjusted higher from the lowest setting to the highest This is performed by placing the bottom of the shock in a vise and using the spanner wrench provided with the kit rotating the adjusting can on the bottom of the shock Rotating clockwise increases the preload and rotating counter clockwise decreases the preload These may need to be adjusted several times to suit rider preferences STEP 8 l STEP 9 1 INSTALLING SHOCKS TO SWING ARM Place a jack under final drive unit and raise the final drive unit so bottom of shocks align with the holes in the clevis brackets of swing arm Place the two 2 x 18 x 2 4 Gr 8 bolts through clevis and shock and fasten with two 2 X 18 nyloc nuts and torque to 55 lbs Fasten air shock to s
8. r of this product 02 01 CALIFORNIA SIDECAR VALKYRIE INTERSTATE TRIKE KIT PARTS LIST 1 BODY FRAME 4 5 16 18 X 3 HHCS 18 5 16 USS Flat Washer 2 4 5 6 C 6 5 16 18 Nyloc Nut 12 56 18 x1 HHCS L 2 5 16 Fender Washer _ 1 Rear Tour Box Bracket 1 With CB 1 Without CB LI 2 Air Shock Front Mounting Bracket 2 Air Shock Rear Mount Bracket 2 3 8 16 x 11 4 HHCS 2 3 846 x 1 1 4 HHCS L 4 3 8 SAE Flat Washer 4 3 8 SAE Flat Washer 12 3 8 16 Nyloc Nut 2 3 8 16 Nyloc Nut 4 Ml0x125x35SHCS 14 M10 Flat Washer L 4 M8 X1 25 Nyloc Nut 14 M8 Flat Washer LI 3 M6 Nyloc Nut AIR SHOCK MOUNT 2 A AIR SHOCK FILLER LINE KIT 1 Valkyrie air shock mount 1 Black air tubing 3 X 1 8 Ll1 Honda O E M air shock 1 Adapter shock to air tube with O ring 1 Air shock filler line kit see 2 A C1 Bag consisting of 11 5 8 18 x 2 1 2 HHCS 11 Ferrel Nut L 1 5 8 18 Nyloc Nut L 1 Ferrel C1 M14 x 1 50 x 55 HHCS 12 Oring 1 M14 x 1 50 Nyloc Nut C1 Air filler assembly 12 M10 x1 25 x 80 HHCS Ll1 Needle valve S S with cap O 4 M10 x125 Nyloc Nut L 2 5 16 Flat Washer S S 12 M10 x1 25 x 100 HHCS CL 11 Needle valve jam nut 16 M10 Flat Washer l1 Brass adapter needle valve to air tube _ 1 Brass compression sleeve L1 Brass compression nut 3 SPRING SHOCKS _ 1 Spanner wrench _ 2 P
9. rogressive shock 12 5 8 18 x 2 1 4 HHCS L 2 5 8 18 Nyloc Nut SWING ARM ASSEMBLY Ll2 Swing arm pivot bolts left right FINAL DRIVE UNIT 8 4 20 Nyloc Nut for Ford Rear Drive 11 Drive shaft fitted with L 1 Yoke O1 U joint C 1 O E M front U joint and yoke modified LI 1 Box of Neapco 1 0189 2 U bolts 4 Nuts and 4 Lock Washers EXHAUST SYSTEM STANDARD EXHAUST SYSTEM OPTIONAL Ll2 Hanger mounts chrome fitted with L See Accessory List 2 5 16 18 X 1 3 4 HHCS 4 5 16 SAE Flat Washer S S 2 5 16 18 Nyloc Nut 7 8 9 10 C 2 3 8 24 x1 HHCS L2 3 8 24 Nyloc Nut BRAKE LINE SYSTEM _ 1 2 piece steel braided brake line 1 21b Residual valve Ll1 M10 X10 banjo bolt with two crush washers WHEELS amp TIRES 8 20 Tapered Lug Nut PASSENGER FOOT REST L 2 Foot rest mount plate L 4 3 8416 x 1 1 2 BHSCS S S O 4 3 8 16 Nyloc Nut 2 M10 x125 x 40 HHCS L 2 M10 Lock Washer MISCELLANEOUS L Instructions L Core Parts List 1 2 ACCESSORY PARTS LIST TRAILER HITCH L 1 Receiver hitch plate aez 6 5 16 18 x 1 HHCS 6 5 16 18 Nyloc Nut C 12 5 16 SAE Flat Washer S S Receiver tongue chrome Receiver pin Receiver pin clip 1 1 7 8 Chrome ball with Lock Washer and Nut CHROME EXHAUST PIPE EXTENSIONS L 2 Turn down extensions chrome 12 4 20 x1 HHCS L 2 4 20
10. sion kit WARNINGS are printed in bold type PLEASE USE EXTREME CARE so as not to damage the part the motorcycle or yourself ALWAYS wear safety glasses when working with hand and power tools and when working with or around any harmful or hazardous materials Additionally when working in and around the fuel system ALWAYS work in a well ventilated area free from sparks and open flames DIRECTIONAL REFERENCES All references to right and left side are as if one is seated on the motorcycle All references to forward mean toward the front of the motorcycle while back means toward the rear of the motorcycle unless otherwise stated SAVING AND DISCARDING PARTS During installation if parts are intended to be saved for later use they are marked SAVE in italics If removed parts are not marked SAVE they may be discarded LIST OF TOOLS AND EQUIPMENT This list contains only those items that might be construed as out of the ordinary for someone repairing a motorcycle ACOPY OF THE O E M SERVICE MANUAL IS ESSENTIAL TO THIS INSTALLATION Trike Installation Trailer Hitch Installation 5 16 drill bit 1 8 X 8 or 3 16 X 8 drill bit Flat Black Spray Paint Floor Jack Ring Pliers Silicone Sealer Super Glue Teflon Sealing Tape IMPORTANT Note to Installing Dealer Please forward the Owner Info Pack to the purchaser of this product It contains valuable information for the end use
11. wing arm with M14 x 1 50 x 55 bolt and M14 x 1 50 nyloc nut and torque to 55 lbs MODIFYING THE EXHAUST SYSTEM Remove chrome covers from each side of the exhaust pipes to expose the individual exhaust tubes where they fit into the muffler Leaving the jack in place under the final drive unit raise the jack higher so exhaust system can be reinstalled Tighten all exhaust bolts at cylinder head and torque to 16 lbs Using an oxy acetylene torch with a rose bud tip carefully heat all three pipes equally until they are red hot When they are sufficiently hot insert a long metal pipe into the muffler to bend mufflers down 2 on both right and left sides Be careful not to burn a hole through the exhaust pipe It will be necessary to tie the motorcycle down and elevate the final drive unit enough for the mufflers to fit into their proper position On right side re heat same three exhaust tubes and again using metal pipe bend muffler out away from center of bike about 2 Again be careful not to burn a hole in the exhaust pipe If exhaust extensions are not being used install muffler hanger brackets now a Slide hanger mounts on from back and join to trike body frame mount with two s x 24 x1 14 long nyloc nuts Do not tighten b Tighten all clamps and rear hanger brackets 6 If exhaust extensions are to be used remove left and right tail pieces and install extensions to mufflers 7 If mufflers do not clear final drive unit or do not
12. ycle Run Arrington VA 22922 PHONE 434 263 8866 FAX 434 263 8877 11
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